Architectural panel fabrication system

ABSTRACT

A fabrication system used for mounting a structural member to a surface including an anchor attached to the surface. The anchor has a pair of sidewalls extending substantially perpendicular therefrom and forming an anchor channel with one or more first flanges formed on at least one of the sidewalls facing the anchor channel. The fabrication system also includes a panel frame having a body for insertion into the anchor channel. The body has at least one lateral surface extending substantially perpendicularly therefrom. First and second sidewalls extend from the body to define a frame channel for receiving an edge portion of the structural member. At least one of the first and second sidewalls has a serrated inner face facing the frame channel.

BACKGROUND OF THE INVENTION

[0001] The present invention relates to a panel fabrication system forattaching architectural wall panels to a building. In particular, thepresent invention relates to a snap-fit assembly that assures properalignment of the panels, ease of installation and lower fabrication andinstallation costs.

[0002] For certain types of buildings, panels are often used to coverthe exterior walls of the building. The panels are used for aestheticpurposes and can be economically beneficial to the owner. Typically asingle panel can be used to cover a large section of the building.Fabrication or (framing) systems are commonly used to attach panels(such as composite, aluminum, glass, stone, precast, etc.) to anexterior surface or a support structure of a building. However, thefabrication systems currently in use are expensive and requireconsiderable time and labor to install and fabricate.

[0003] Generally most fabrication systems for attaching panels to abuilding support utilize a screw-on system or a compression fit systemrequiring a screw. Systems utilizing screws and other fasteners addlabor costs because of additional time required for installation andfabrication. Generally, after the panels are installed within thefabrication system, a leveling and alignment process of the panelsoccurs. The leveling and the alignment process further lengthens theperiod of time required for proper installation. Furthermore, if thepanel needs to be removed due to damage, most fabrication systemsrequire the removal of numerous panels to replace the damaged one. Thisresults in increased maintenance costs for maintaining the fabricationsystem.

[0004] Existing systems typically allow condensation to drain down thepanel and/or the building on which the panel is mounted. Thecondensation drainage often leads to future leakage and other waterdamage. Systems that use caulk as a sealant potentially leads to caulkmigrating past the face of the panel. The caulk also absorbscontaminants as it ages and causes discoloration and breaking down ofthe caulk, thereby eliminating the aesthetic benefits of the fabricationsystem. Dry set systems often fail due to improper panel alignment whichleads to future leakage within the framing system. Furthermore, currentsystems use labor intensive methods to seal the corners of the panel orbypass sealing the corners of the panels altogether. The labor intensivemethods of sealing lead to increased fabrication costs while not sealingthe panels lowers fabrication costs but leads to future fabricationsystem failure.

[0005] Many fabrication systems utilize a multi-bracket attachmentsystem requiring the use of several different lengths of brackets whichhave to be aligned at different locations along the building support.This method increases both the labor costs for engineering, fabricationand installation. Also, this method is quite susceptible tomisalignment, leading to the panels being installed in an improperplane. Existing fabrication systems are often designed for use with aspecific type of panel. This limits the versatility of the fabricationsystem and leads to increased costs if different types of panels areused for a single structure. Most systems also utilize aluminumextrusions which are not as resilient or cost effective as otheralternatives.

[0006] The prior art systems for attaching a panel to a building utilizemethods that are labor intensive, have an inconsistency of quality, andhave higher maintenance and labor costs. Accordingly, a panelfabrication system is needed in the art that is inexpensive and reducesthe time and ease of installation and fabrication. The prior art lacks aframing system that is strong, maintains quality, insures proper panelalignment and has low maintenance and labor costs.

BRIEF SUMMARY OF THE INVENTION

[0007] The present invention relates to an extruded fabrication systemfor mounting a structure to a member surface. The attachment systemincludes an anchor attached to the surface. The anchor has a pair ofsidewalls extending substantially perpendicular therefrom. The pair ofsidewalls form an anchor channel and have one or more first flangesformed on at least one of the sidewalls facing the anchor channel. Theattachment system also includes a panel frame having a body. The bodyhas at least one lateral surface extending substantially perpendicularlyand the body is inserted into the anchor channel. The body has first andsecond sidewalls extending from the body. The first and second sidewallsdefine a frame channel for receiving edge portion of the structuralmember. At least one of the first and second sidewalls has a serratedinner face facing the frame channel.

[0008] In one preferred embodiment of the present invention a gasket isengaged to the second sidewall of the panel frame to form a sealadjacent the structural member. The gasket includes a pair of sidewallsextending substantially perpendicular therefrom. The pair of sidewallsform a gasket channel. One or more third flanges are formed on at leastone of the sidewalls for engaging the second sidewall of the panelframe.

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The present invention will be further explained with reference tothe drawing figures listed below, wherein like structure is referencedby like numerals throughout the several views.

[0010]FIG. 1 is a perspective view of a building using an inventivepanel fabrication system.

[0011]FIG. 2 is an exploded end view of an exemplary embodiment of thefabrication system of the present invention.

[0012]FIG. 3 is a end view of an anchor used in the inventivefabrication system of FIG. 2.

[0013]FIG. 4 is a end view of a panel frame used in the inventivefabrication system of FIG. 2.

[0014]FIG. 4A is an enlarged end view of a portion of the panel frametaken from section 4A of FIG. 4.

[0015]FIG. 5 is an assembled end view of the fabrication system of FIG.2.

[0016]FIG. 6 is an assembled end view of a second exemplary embodimentof the fabrication system of the present invention.

[0017]FIG. 7A is a top view of a structural member 12 prior to assembly.

[0018]FIG. 7B is a perspective view of a folded structural member foruse in the inventive fabrication system.

[0019] While some of the above-identified figures set forth preferredembodiments of the invention, other embodiments are also contemplated,as noted in the discussion. In all cases, this disclosure presents theinvention by way of representation and not limitation. It should beunderstood that numerous other modifications and embodiments can bedevised by those skilled in the art, which fall within the scope andspirit of the principles of the invention.

DETAILED DESCRIPTION

[0020]FIG. 1 is a perspective view of a building 10 using an inventivefabrication system (not shown) to attach structural members 12 to thebuilding 10. The building 10 has at least four support walls 14 and aroof 16. The structural members 12 are attached to the support walls 14of the building 10. In FIG. 1, the structural members 12 may includecomposite panels 18, glass windows 20 or other ornamental or functionalbuilding components. Also, brick 22 is mounted to the building 10 at thecorners. The building 10 is used as an example of a building utilizingthe inventive fabrication system. Those skilled in the art willrecognize that the present invention may be employed on buildings ofvarying size and shape, as well as in connection with different types ofstructural members, including composite, aluminum, glass, stone, andprecast. The structural members may be attached to other surfaces on thebuilding 10, including the support structure, building support, or agenerally vertical surface. Furthermore, the structural members may beattached to any structure, such as bridges or vehicles, and can be usedfor other forms of construction assemblies.

[0021]FIG. 2 shows an exploded end view of an exemplary embodiment of afabrication system 24. The fabrication system 24 includes an anchor 26(secured to a surface 27 of an underlying support structure), at leastone panel frame 28, a gasket 30, and the structural member 12. FIGS. 3and 4 further illustrate the anchor 26 and the panel frame 28,respectively. The anchor 26, the panel frame 28 and the gasket 30 arepreferably made of plastic and are formed by an extrusion manufacturingtechnique. However, those skilled in the art will recognize thefabrication system 24 can be extruded using a variety of materials, forexample, PVC, aluminum and steel, and the fabrication system 24 isadaptable to be installed with different types of materials, such ascomposite, glass, precast or eface.

[0022] The anchor 26 has a base plate 32. A first sidewall 34 and asecond sidewall 36 extend from the base plate 32 to form an anchorchannel 38. The sidewalls 34 and 36 lie substantially perpendicular tothe base plate 32. The first sidewall 34 has an inner face 40 and thesecond sidewall has an inner face 42. The inner faces 40 and 42 faceinward toward the anchor channel 38. First flanges 44 are formed on oneor both of the inner faces 40 and 42. The anchor channel 38 receives thepanel frame 28. In the exemplary embodiment shown in FIG. 2, two sets offirst and second sidewalls 34 and 36 extend from the base plate 32 toform two anchor channels 38. Although FIG. 2 illustrates two firstflanges 44 formed on the sidewalls 34 and 36, those skilled in the artwill recognize any number of flanges can be formed on the sidewall andthat the flanges 44 can be formed on one or both sidewalls.

[0023] The panel frame 28 includes a body 46, a first sidewall 48 and asecond sidewall 50. The body 46 has a first end 52 and a second end 54.The first end 52 is preferably tapered to form a neck 55 proximate thesecond end 54. A lateral surface 57 extends perpendicularly from thebody 46 of the panel frame 28. One or more second flanges 56 are formedadjacent the neck 55 such that the lateral surface 57 is part of thesecond flanges 56. When the fabrication system 24 is assembled, the body46 of the panel frame 28 is inserted into the anchor channel 38 of theanchor 26 and the lateral surface 57 of the second flanges 56 engageswith the first flanges 44 of the anchor 26, thereby securing the panel28 to the anchor 26 by mechanical engagement. Those skilled in the artwill recognize any number of flanges may be formed along the length ofthe body of the panel frame.

[0024] The first sidewall 48 and the second sidewall 50 of the panelframe 28 extend from the second end 54 of the body 46. The sidewalls 48and 50 preferably lie substantially parallel to the body 46. Eachsidewall has a first end 58, 59 and a second end 60, 61. The sidewalls48 and 50 form a frame channel 62. Preferably, the second end 60 of thefirst sidewall 48 is further form the body 46 than the second end 61 ofthe second sidewall 50. The first sidewall 48 has an inner face 64 andthe second sidewall 50 has an inner face 66 with the inner faces 64 and66 facing inwardly toward the frame channel 62. The inner faces 64 and66 are serrated with a plurality of flanges 68, or teeth, formed on theinner faces 64 and 66. The flanges 68 preferably lie along the entirelength of the sidewalls 48 and 50. When the fabrication system 24 isassembled, the structural member 12 is inserted into the frame channel68 of the panel frame 28. The flanges 68 grip the structural member 12to hold the structural member 12 within the frame channel 62. FIG. 4Ashows an enlarged end view of the second sidewall 50 of the panel frame28 with the flanges 68 along the inner face 66. Although FIG. 2 showsserration on the first and second sidewalls 48 and 50, those skilled inthe art will recognize the flanges 68 can be formed on one or bothsidewalls.

[0025] As seen in FIG. 4, a panel flange 70 extends from the second end60 of the first sidewall 48. The panel flange 70 lies substantiallyperpendicular to the first sidewall 48 and extends away from the framechannel 62. A gasket seat 72 extends from the second end 61 of thesecond sidewall 50 and away from the frame channel 62. The gasket seat72 includes a shoulder 74, an upper arm 76 and a lower arm 78. Theshoulder 74 is attached to the second end 61 of the second sidewall 50.The shoulder 74 extends away from the frame channel 62 and liessubstantially perpendicular to the second sidewall 50. A ledge 80 isformed on the shoulder 74. The upper arm 76 is attached to the shoulder74. The upper arm 76 extends away from the body 46 and liessubstantially parallel to the first sidewall 48. The lower arm 78 isattached to the upper arm 76. The lower arm 78 extends at an acute anglefrom the upper arm 76 towards the second end 60 of the first sidewall48.

[0026] As seen in FIG. 2, the gasket 30 includes a base plate 82, afirst sidewall 84 and a second sidewall 86. The first sidewall 84 isattached one end of the base plate 82. The first sidewall 84 extendsfrom the base plate 82 and lies substantially perpendicular to the baseplate 82. The second sidewall 86 is attached to the base plate 82. Thesecond sidewall 86 extends from the base plate 82 and lies substantiallyperpendicular to the base plate 82. The first and second sidewall 84 and86 form a gasket channel 90. In the exemplary embodiment of thefabrication system 24 shown in FIG. 2, two sets of first and secondsidewalls 84 and 86 extend from the base plate 82 to form two gasketchannels 90.

[0027] The first sidewall 84 has an inner face 92 and the secondsidewall 86 has an inner face 94. The inner faces 92 and 94 face inwardtowards the gasket channel 90. The first sidewall 84 has an end 96opposite the base plate 82 and the end 96 is tapered. The secondsidewall 86 has an end 98 opposite the base plate 82 and the end 98 istapered. A third flange 100 extends from the end 98 of the secondsidewall 86 towards the gasket channel 90. Preferably, the secondsidewall 86 has a height greater than a height of the first sidewall 84.When the fabrication system 24 is assembled, the third flange 100 of thegasket channel 90 engages the gasket seat 72 of the panel frame 28.

[0028] Preferably, the structural member 12 has a body 102 and at leastone support edge 104 (see FIG. 2). The structural member 12 ispreferably a composite panel. However, two different types of panels maybe used within one fabrication system. For example, the structuralmember 12A may be aluminum and the structural member 12B may be glass.The support edge 104 of the structural member 12 extends from one end ofthe body 102 and has an inner face 103. The support edge 104 liessubstantially perpendicular to the body 102. The support edge 104 has alength. Preferably, the length of the frame channel 62 is the same. Oncethe fabrication system 24 is assembled, the support edge 104 of thestructural member 12 is inserted into the frame channel 62. The flanges68 of the panel frame 28 grip the support edge 104 to hold thestructural member 12 in place. An end 105 of the support edge 104 abutsa bottom 63 of the frame channel 62.

[0029] Those skilled in the art will recognize that other means may beused to secure the structural member 12 within the frame channel 62 ofthe panel frame 28. For example, a connector or adapter may replace thesupport edge 104. The connecter is attached to the body of thestructural member and the connecter is inserted into the frame channeland gripped by the flanges to hold the structural member in place.

[0030]FIG. 5 is an assembled end view of the fabrication system 24. Theanchor 26 is attached to a building support 106 of the building 10. Theanchor 26 can be attached to the building support 106 eitherhorizontally or vertically so that once the structural members 12 areattached, the structural members 12 run horizontally or vertically. Afastener 108 (such as a screw, bolt, rivet, etc.) is used to attach thebase plate 32 of the anchor 26 to the building support 106. An adhesive110 is used in the exemplary embodiment around the fastener 108 to helpsecure the anchor 26 to the building support 106. Those skilled in theart will recognize the fabrication system 24 can be attached in otherways, and to other surfaces such as the exterior wall of the building orany vertical surface.

[0031] One panel frame 28 is secured within each anchor channel 38. Thebody 46 of the panel frame 28 is inserted into the anchor channel 38.The first flanges 44 of the anchor 26 engage the lateral surface 57 ofthe second flanges 56 of the body 46 to secure the panel frame 28 withinthe anchor channel 38. An adhesive 112, preferably a silicone bead, isdeposited within the anchor channel 38 to help the panel frame 28 toanchor 26.

[0032] The frame channel 62 receives the support edge 104 of thestructural member 12. The flanges 68 of the sidewalls 48 and 50 grip thestructural member 12 to secure the structural member 12 within the framechannel 62. Once the structural member 12 is secured within the framechannel 62, the inner face 64 of the panel frame 28 abuts the inner face103 of the edge 104 of the structural member 12. In the exemplaryembodiment shown in FIG. 5, two adjacent panel frames 28 are mounted,although other embodiments exist for the anchor allowing any number ofpanel frames to be used. Preferably, the two structural members 12secured by the panel frames 28 extend in opposite directions.

[0033] The gasket 30 is preferably used in the fabrication system 24when the anchor 26 has at least two anchor channels 38 securing twopanel frames 28. The second sidewalls 50 of the two panel frames 28 faceeach other. The gasket 30 is attached to the gasket seat 72 on eachsecond sidewall 50. The gasket channels 90 of the gasket 30 engage theledge 80 of the gasket seat 72 on the panel frame 28. The third flange100 on the second sidewall 86 engages the ledge 80 of the gasket seat72. The gasket seat 72 is secured within the gasket channel 90 to securethe gasket 30 to the panel frame 28. An adhesive, preferably a siliconebead, is placed in each gasket channel 90 to help secure the gasket 30to the panel frame 28 and create a moisture seal adjacent the structuralmembers.

[0034] As seen in FIG. 5, The assembled fabrication system 24 forms aninner cavity 116. The cavity 116 is formed by the base plate 32 of theanchor 26, the second sidewalls 36 of the anchor 26, the secondsidewalls 50 of the panel frame 28, the second sidewalls 86 of thegasket 30 and the base plate 82 of the gasket 30. Condensation which maycollect under the structural members 12 travels through the cavity 116.The cavity 116 prevents moisture and condensation from traveling alongthe front or the rear of the structural members 12.

[0035]FIG. 6 is an assembled end view of another exemplary embodiment ofan inventive fabrication system 200. The fabrication system 200 is usedin conjunction with the coupling of different facade or structuralmaterials, such as a panel system and a window wall system 202. Thewindow wall system 202 preferably holds a glass wall 204 and attaches tothe support wall 14 of the building 10. Although the window wall system202 is used as an example in FIG. 6, those skilled in the art willrecognize that other structural members may be used in conjunction withthe fabrication system 200.

[0036] The fabrication system 200 includes an anchor 226, the panelframe 28 and the structural member 12. The anchor 226 has one anchorchannel 238 formed by the first and second sidewalls 234 and 236. Thebody 46 of the panel frame 28 is inserted into the anchor channel 238and snap-fit into position. The support edge 104 of the structuralmember 12 is secured within the frame channel 62. Preferably, a singlestructural member 12 is used in the fabrication system 200, with theanchor 226 attached as discussed above.

[0037] Once the fabrication system 200 is assembled, the fabricationsystem is attached to the window wall system 202. An adhesive ball 206secures the window wall system 202 to the fabrication system 200. In theexemplary embodiment, the window wall system 202 is attached to thesecond sidewall 50 of the panel frame 28. Caulk 208 is used to provide amoisture seal between the fabrication system 200 and the window wallsystem 202. A weep hole 210 is formed in the fabrication system 200 andprovides a gutter system to prevent the drainage of condensation on theface of the structural member 12. The weep hole extends through thefirst sidewall 48 of the panel frame 28 and the support edge 104 of thepanel 12. A screen 212 is placed over one end of the weep hole 210 toprevent insects or other debris from passing through the weep hole 210.

[0038]FIG. 7A is a top view of the structural member 12 in a flatposition. One process for forming the structural member having the body102 and at least one support edge 104 is a folding method to create anenvelope pan corner. A notch 214 is formed along one edge of thestructural member 12 proximate a corner of the structural member betweena first edge 216 and a second edge 218. The notch is preferablytriangular shaped.

[0039]FIG. 7B shows a folded structural member 12 forming an envelopepan corner 220. Both edges 216 and 218 are folded substantially 90degrees to form the support edge 104. The ends of each edge meet to forma seam 222 along one support edge 104. Moving the seam 222 of thestructural member 12 from the corners of the structural member providesgreater strength, and results in less likelihood of water penetrationand a sharper profile at the corners. In addition, a plate 224 may befastened to the support edge 104 with a fastener 226 (preferably arivot). The plate provides support and strength and prevents waterpenetration. Once the structural member 12 is folded, the support edge104 is inserted into the frame channel 62 of the panel frame 28.

[0040] The fabrication system of the present invention insures properalignment of structural members on a building. The anchor is preferablypre-located and pre-positioned on the building prior to assembling thefabrication system and inserting the structural member. Pre-positioningensures proper location of the anchor, and thus of the fabricationsystem, prior to panel installation. Since the structural members aresecured to the panel frames, no post-assembly alignment is necessary.The use of the panel frame set within the anchor provides a properlypositioned frame channel for receiving the structural member. Once thestructural members are inserted within the frame channel of the panelframe the corners of the panel are automatically aligned and the panelis square on the building. The panel flange provides another means forinsuring the structural member is properly aligned within the panelframe. The snap-fit assembled fabrication system ensures proper plane ofthe structural member once assembled and mounted to the building.Pre-location of the anchor reduces installation time and labor costs.

[0041] The use of flanges within the anchor channel and the gasketchannel, including the serrated frame channel, allows the fabricationsystem parts to be snap-fit into position. The components of thefabrication system do not require pop rivets or screws, a backup plate,an attachment bracket or drill holes to assemble the fabrication system.The flanged channels eliminate the requirement for multi-sized panelclips and mechanical screw fasteners, thereby allowing easy and quickinstallation to reduce labor time and costs. The flanged channelsprovide non-mechanically applied snap-in connection between thecomponents of the fabrication system, in particular the panel frame andthe anchor.

[0042] The length of the anchor channel and the length of the panelframe can be adjusted to meet various installation requirements e.g.,may be as long as edge support of structural member. Furthermore, theanchor, the panel frame and the gasket of the fabrication system mayhave a length that runs the entire height of the building or thestructural member such that a single fabrication system is used for eachstructural member. Or multiple anchors, panel frames and gaskets runningthe entire building may be used to attach a single structural member ofthe building.

[0043] The gasket seat of the panel frame provides a proper lock toprevent migration of the gasket. The gasket provides a moisture seal forthe fabrication system. In particular, the cavity allows an area formoisture and condensation to travel without traveling along the panel orthe building. The cavity acts as a buffer system for moisture to becontained within the cavity and not on the face of the panel or thebuilding. This eliminates any discoloring on the panel surface due toexterior drainage. The gasket is preferably formed from a flexiblematerial (e.g., silicone) and can thus be rolled into place and snap-fitinto position within the fabrication system. The gasket clips onto itsrespective gasket seat and locks into place. The ability to quicklyinstall the gasket reduces labor costs at the time of installation andspeeds up the installation process. The adhesive is applied within thegasket channel to provide further adhesion and act as a sealant. Thegasket and the adhesive further provide improved and proper adhesiveseal control. The use of the gasket and the adhesive in combinationkeeps the gasket in position and eliminates discoloring problems due topollutants and migration of moisture past the face of the structuralmember. The adhesive applied within the anchor channel also provides amoisture seal.

[0044] The anchor and panel frame of the fabrication system arepreferably made of a high density PVC. The PVC material allows for moreresiliency and flexibility of the fabrication system. The fabricationsystem will absorb the stress due to expansion and contraction off thepanel joints. Thus, pillowing and/or buckling of the surface of thestructural member will be reduced. In addition, the PVC material islighter than aluminum, thus reducing the weight of the fabricationsystem. The high density PVC material provides high impact resistance,proper thermal break, resiliency for locking positions and preventsbowing at the panel face.

[0045] A significant advantage of the inventive fabrication system is adamaged panel may be removed individually. The ability to remove panelsor individually from the fabrication system reduces maintenance costsfor the building. Overall, the ease of installation at a constructionsite allows for reduced labor and quicker installation times. Also,potential damage to panels may be reduced because lengthy storage onsite is no longer necessary.

[0046] Although the present invention has been described with referenceto preferred embodiments, workers skilled in the art will recognize thatchanges may be made in form and detail without departing from the spiritand scope of the invention.

1. A fabrication system for mounting a structural member to a surface,the fabrication system comprising: an anchor attached to the surface andhaving a pair of sidewalls extending substantially perpendiculartherefrom, the pair of sidewalls forming an anchor channel and havingone or more first flanges formed on at least one of the sidewalls facingthe anchor channel; and a panel frame having a body adapted forinsertion into the anchor channel, the body having at least one lateralsurface extending substantially perpendicularly therefrom, the bodyhaving first and second sidewalls extending from the body to define aframe channel for receiving an edge portion of the structural member andat least one of the first and second sidewalls having a serrated innerface facing the frame channel.
 2. The fabrication system of claim 1wherein the anchor channel is a first anchor channel and the anchor hasan additional pair of sidewalls thereon which form a second anchorchannel spaced from and parallel to the first anchor channel.
 3. Thefabrication system of claim 1 wherein the lateral surface on the body ofthe panel frame engage the first flanges within the anchor channel. 4.The fabrication system of claim 1 wherein an adhesive is applied tofurther secure the panel frame to the anchor.
 5. The fabrication systemof claim 1 wherein the structural member has a support edge extendingfrom the structural member and the support edge is secured within theframe channel of the panel frame.
 6. The fabrication system of claim 1wherein the panel frame includes a panel flange extending substantiallyperpendicular from the first sidewall away from the frame channel. 7.The fabrication system of claim 6 wherein the panel flange abuts thestructural member when the structural member is secured within the framechannel.
 8. The fabrication system of claim 1, and further comprising: agasket engaged to the second sidewall of the panel frame to form a sealadjacent the structural member.
 9. The fabrication system of claim 8wherein the gasket includes a pair of sidewalls extending substantiallyperpendicular therefrom, the pair of sidewalls forms a gasket channeland one or more third flanges are formed on at least one of thesidewalls for engaging the second sidewall.
 10. The fabrication systemof claim 9 wherein the gasket channel is a first gasket channel and thegasket has an additional pair of sidewalls thereon which form a secondgasket channel spaced from and parallel to the first gasket channel. 11.The fabrication system of claim 9 wherein an adhesive is applied withinthe gasket channel to further secure the gasket to the second sidewalland form the seal.
 12. The fabrication system of claim 8 wherein thepanel frame includes a gasket seat extending from the second sidewallaway from the frame channel.
 13. The fabrication system of claim 12wherein the gasket seat further comprises: a shoulder extendingsubstantially perpendicular from the second sidewall of the panel frameand away from the frame channel, the shoulder forming a ledge; an upperarm extending substantially perpendicular from the shoulder and awayfrom the body; and a lower arm extending at an acute angle from theupper arm toward the first sidewall.
 14. The fabrication system of claim13, wherein the gasket engages the ledge of the gasket seat to form theseal.
 15. The fabrication system of claim 1 wherein the first sidewallof the panel frame is higher than the second sidewall of the panelframe.
 16. The fabrication system of claim 1 wherein the anchor channelis a first anchor channel and the anchor has an additional pair ofsidewalls thereon which form a second anchor channel spaced from andparallel to the first anchor channel, the panel frame is a first panelframe and the first panel frame is secured within the first anchorchannel, and the fabrication system further comprises: a second panelframe being secured within the second anchor channel wherein the framechannel of the first panel frame receives an edge portion of a firststructural member and the frame channel of the second panel framereceives and edge portion of a second structural member; a gasket havingtwo pairs of sidewalls extending substantially perpendicular therefrom,the pairs of sidewalls form a first gasket channel and a second gasketchannel, one or more third flanges are formed on at least one of thesidewalls of each pair wherein the first gasket channel engages thesecond sidewall of the first panel frame and the second gasket channelengages the second sidewall of the second panel frame to form a sealadjacent the structural members; and an adhesive is disposed within thefirst and second gasket channels to further secure the gasket to thesecond sidewalls and form the seal.
 17. A method for attaching astructural member having an edge portion to a surface, the methodcomprising: providing an anchor having a pair of sidewalls extendingsubstantially perpendicular therefrom, the pair of sidewalls forming ananchor channel and having one or more first flanges formed on at leastone sidewall facing the anchor channel; securing the anchor to thesurface; providing a panel frame having a body, the body having at leastone lateral surface extending substantially perpendicularly therefrom,the body having first and second sidewalls extending from the body todefine a frame channel and at least one of the first and secondsidewalls has a serrated inner face facing the frame channel; securingthe panel frame to the anchor wherein the body of the panel frame isinserted into the anchor channel of the anchor; and securing the edgeportion of the structural member within the frame channel of the panelframe wherein the edge portion is engaged by the serrated face.
 18. Themethod of claim 17 wherein the anchor channel is a first channel and theanchor has an additional pair of sidewalls thereon which form a secondanchor channel spaced from and parallel to the first anchor channel. 19.The method of claim 17 wherein the securing the panel frame stepcomprises engaging the lateral surface on the body of the panel framewith the first flanges within the anchor channel.
 20. The method ofclaim 17, and further comprising: disposing an adhesive within theanchor channel to secure the panel frame to the anchor.
 21. The methodof claim 17, and further comprising: engaging a gasket to the secondsidewall of the panel frame to form a seal adjacent the structuralmember.
 22. The method of claim 21, and further comprising: disposing anadhesive between the gasket and the panel frame prior to engaging thegasket to the second sidewall of the panel frame.
 23. The method ofclaim 21 wherein the second sidewall of the panel frame includes agasket seat comprising: a shoulder extending substantially perpendicularfrom the second sidewall of the panel frame and away from the framechannel, the shoulder forming a ledge; an upper arm extendingsubstantially perpendicular from the shoulder and away from the body;and a lower arm extending at an acute angle from the upper arm towardthe first sidewall of the panel frame.
 24. The method of claim 23, andfurther comprising: abutting the gasket against the ledge of the gasketseat when the gasket is engaged with the panel frame.
 25. The method ofclaim 17 wherein the structural member has a support edge extending fromthe structural member, and further comprising: securing the support edgewithin the frame channel of the panel frame.
 26. The method of claim 17wherein a panel flange extends substantially perpendicular from thefirst sidewall of the panel frame and away from the frame channel. 27.The method of claim 26, and further comprising: abutting the panelflange against the structural member when the structural member issecured within the frame channel of the panel frame.
 34. A method forattaching a structural member having an edge portion to a surface, themethod comprising: providing an anchor having at least two pairs ofsidewalls extending substantially perpendicular therefrom, one pair ofsidewalls forming a first anchor channel and the other pair of sidewallsforming a second anchor channel and the anchor having one or more firstflanges formed on at least one sidewall of each pair sidewalls, theflanges facing the anchor channel; securing the anchor to the surface;providing a first panel frame and a second panel frame, the panel frameshaving a body, the body having at least one lateral surface extendingsubstantially perpendicularly therefrom, the body has first and secondsidewalls extending from the body to define a frame channel and at leastone of the first and second sidewalls has a serrated inner face facingthe frame channel; securing the first panel frame within the firstanchor channel and securing the second panel frame within the secondanchor channel wherein the lateral surface of the panel frame engagesthe first flanges within the anchor channel; securing the edge portionof the structural member within the frame channel of the panel framewherein the edge portion is engaged by the serrated face; providing agasket having two pairs of sidewalls extending substantiallyperpendicular therefrom, one pair of sidewalls forming a first gasketchannel and the other pair of sidewalls forming a second gasket channel,and one or more third flanges are formed on at least one of thesidewalls of each pair; and engaging the gasket to the panel frameswherein the first gasket channel engages the second sidewall of thefirst panel frame and the second gasket channel engages the secondsidewall of the second panel frame to form a seal adjacent thestructural members.